torque LEXUS SC400 1991 Service Manual PDF

Parts Inspection
(Horn Switch)
INSPECTION OF HORN SWITCH
INSPECT HORN SWITCH
(a) Disconnect the negative (±) terminal from the battery.
(b) Remove the left and right covers from the steering wheel.
(c) Using a torx wrench, loosen the four bolts.
(d) Pull up the horn pad and place it on the steering column as shown.
HINT: Do not disconnect the connector from the horn pad.
(e) Disconnect the connector from the slip ring.
(f) Check that there is no continuity between terminal 6 of the
connector and body ground.
(g) Check that there is continuity between terminal 6 of the connector and body ground when the horn contact plate is
pressed against the steering spoke assembly.
If continuity is not as specified, repair or replace the steering
wheel or wire harness as necessary.
(h) Install the horn pad in place and using a torx wrench, tighten the four bolts.
Torque: 7.1 N Vm (72 kgf Vcm, 62 in. Vlbf)
(i) Install the left and right covers.
(j) Connect the negative (±) terminal to the battery.
(Horn)
INSPECTION OF HORN
INSPECT HORN OPERATION
Connect the positive (+) lead from the battery to the terminal
and negative (±) lead to the horn body and check that the
horn blows.
If operation is not as specified, replace the horn.
±
BODY ELECTRICAL SYSTEM HORN SYSTEMBE±263
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EQUIPMENT (Cont'd)
PartNote
Torque wrench
Clip removerFor removing cowl louver
Masking tapeRear window defogger wire
Tim foilRear window defogger wire
SSM (SPECIAL SERVICE MATERIALS)
Part NamePart No.Use etc.
Adhesive 1324,
Three bond 1324 or equivalent08833±00070Power seat housing set nut, Power seat slide and vertical
motor set screw
Adhesive 1344,
Three bond 1344,
Loctite 242 or equivalent
08833±00080Low oil pressure warning switch Water temperature
sender gauge
Dupont paste No. 4817±Rear window defogger wire
±
BODY ELECTRICAL SYSTEM PreparationBE±9
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5. REMOVE COMBINATION SWITCH ASSEMBLY(a) Remove four screws.
(b) Disconnect connectors.
(See page BE±41)
HINT: Since the airbag connector has a 2±stage lock, remove
the 1st stage lock, and disconnect the connector.
(c) Remove combination switch assembly from steering column.
HINT: Pull the wire harness spool body to forward and re-
move wire harness spool body from steering column.
INSPECTION OF COMBINATION SWITCH
For installation, follow the removal procedure in reverse.
(MAIN POINT OF INSTALLATION)
1. ADJUSTMENT OF SPIRAL CABLE (a) Check that the front wheels are facing straight ahead.
(b) Turn the spiral cable counterclockwise by hand until itbecomes harder to turn the cable.
(c) Then rotate the spiral cable clockwise about 3 turns to align the red mark.
HINT:
w The spiral cable will rotate about 3 turns to either left or
right of the center.
w The connector should be straight up.
(d) Install the steering wheel so that the match marks will not be misaligned.
2. INSTALL STEERING SET NUT
Torque: 35 N Vm (360 kgf Vcm, 26 ft Vlbf)
3. INSTALL STEERING WHEEL CENTER PAD
Torque the torx screws.
Torque: 7.1 N Vm (75 kgf Vcm, 62 in.lbf) V
BE±40±
BODY ELECTRICAL SYSTEM Lighting System
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REMOVAL OF WIPER MOTOR AND LINK
ASSEMBLY
1. REMOVE WIPER ARM AND BLADE ASSEMBLY
2. REMOVE COWL TOP LOUVER(a) Remove hood to cowl seal.
(b) Remove cowl louver.HINT: Raise the front side of the cowl louver up and remove
the cowl louver.
3. REMOVE WIPER MOTOR AND LINK ASSEMBLY (a) Remove five set bolts.
(b) Disconnect connector.
(c) Raise the front side of the wiper motor and link assembly
up and remove the wiper motor and link assembly.
(d) Remove wiper motor cover.
INSTALLATION OF WIPER MOTOR AND
LINK ASSEMBLY
1. INSTALL WIPER MOTOR AND LINK ASSEMBLY (a) Install wiper motor cover.
(b) Install wiper motor and link assembly.
(c) Connect the connector.
(d) Install and torque the four bolts.
Torque: 5.4 N Vm (55 kgf Vcm, 48 in. Vlbf)
2. INSTALL COWL LOUVER
(a) Install cowl louver. HINT: With the front side of the louver raised, install the
protector on the glass, then push the louver down.
(b) Install hood to cowl seal.
BE±88
±
BODY ELECTRICAL SYSTEM Wiper and Washer System
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3. INSTALL WIPER ARM AND BLADE ASSEMBLY(a) Install the wiper arms and bl ades, and operate the
wipers once and turn the wiper switch OFF.
(b) Adjust the installation positions of the wiper arms and
blades to the positions shown in the figure.
(A) Approx. 44.0 mm (1.734 in.)
(B) Approx. 45.0 mm (1.773 in.)
Torque the nut.
Torque: 20 N Vm (205 kgf Vcm, 15 ft Vlbf)
DISASSEMBLY OF WIPER MOTOR AND
LINK ASSEMBLY
1. REMOVE CASE ROD AND WIPER LINK NO.1 ROD
2. REMOVE WIPER MOTOR
(a) Remove wire harness clamp and three bolts and a nut.
(b) Remove wiper motor.
ASSEMBLY OF WIPER MOTOR AND
LINK ASSEMBLY
1. INSTALL WIPER MOTOR(a) Connect the wiper motor connector.
(b) Operate the wiper motor once and turn the wiper switch OFF.
(c) Install wiper motor as shown in the figure.
(d) Install wire harness clamp.
(e) Install three bolts and a nut.
Torque:
BOLT: 5.4 N Vm (55 kgf Vcm, 48 in. Vlbf)
NUT: 17 N Vm (175 kgf Vcm, 13 ft Vlbf)
2. INSTALL CASE ROD AND WIPER LINK NO.1 ROD
±
BODY ELECTRICAL SYSTEM Lighting SystemBE±89
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TRAC PUMP AND ACCUMULATOR
TRAC PUMP AND ACCUMULATOR
REMOVAL AND INSTALLATION
BR0F9±03
Remove and install the part, as shown.
MAIN POINTS OF REMOVAL AND
INSTALLATION
1. DRAIN OUT HIGH PRESSURE FLUID
(a) Connect a vinyl tube to the TRAC actuator bleeder plug, then
loosen the bleeder plug.
(b) When the fluid has flowed out, tighten the bleeder plug.
CAUTION: Since the fluid is under high pressure, it could
spray out with great force, so be careful.
2. DISCONNECT AND CONNECT BRAKE LINE Using SST, disconnect and connect the brake line from/to the
accumulator.
SST 09751±36011
Torque: 15 N Vm (155 kgf Vcm, 11 ft Vlbf)
3. BLEED BRAKE SYSTEM AND TRAC SYSTEM
(See page BR±8)
BR±162
±
BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC)
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TORQUE SPECIFICATIONS
BR03B±0G\
 
\

\
Part tightened
 

N
Vm
 

kgf
Vcm
 

ft
Vlbf
\
 \
Master cylinder x Piston stopper bolts 10 100 7
\
 \
Master cylinder x Reservoir 1.7 17.5 15.2 in. Vlbf
\
 
\

\
Master cylinder x Brake booster 

13 

130 

9
\
 \
Brake tube union nut 15 155 11
\
 \
Brake booster clevis lock nut 25 260 19
\
 \
Brake booster x Pedal bracket 15 150 11\
 
\

\
Bleeder plug (TRAC actuator and TRAC accumulator)
 

8.3
 

85
 

74 in.
Vlbf
\
 \
Bleeder plug 11 11 0 8
\
 \
Front disc brake torque plate x Steering knuckle 11 8 1,200 87
\
 \
Front disc brake cylinder installation bolt 34 350 25\
 
\

\
Front disc brake cylinder x Flexible hose bolt
 

30
 

310
 

22
\
 \
Rear disc brake torque plate x Axle carrier 104 1,065 77
\
 \
Rear disc brake cylinder installation bolt 34 350 25
\
 
\

\
Rear disc brake x Flexible hose union bolt 

30 

310 

22
\
 \
Parking brake lever x Floor 59 600 43
\
 \
Parking brake cable No.1 x Floor 9 80 69 in.
Vlbf
\
 \
Parking brake cable retainer x Floor 5.4 55 48 in. Vlbf\
 
\

\
Parking brake cable clamp x Floor
 

19
 

190
 

14
\
 \
ABS actuator x Actuator bracket 5.4 55 48 in.
Vlbf
\
 \
ABS actuator bracket x Body 19 195 14
\
 
\

\
Front speed sensor installation bolt 

7.8 

80 

69 in.
Vlbf
\
 \
Rear speed sensor installation bolt 7.8 80 69 in. Vlbf
\
 \
TRAC pump bracket x Body 19 195 14
\
 \
TRAC pump or accumulator x Union bolt 46 465 34
BR±230±
BRAKE SYSTEM SERVICE SPECIFICATIONS
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EQUIPMENT
BR03K±03\
 
\

\
Torque wrench
 


\
 
\

\
Micrometer
 

Brake disc
\
 
\

\
Dial indicator
 

Brake disc
\
 
\

\
Vernier calipers 

Brake disc
LUBRICANT
BR03L±03
 

Item 

Capacity 

Classification
 Brake fluid ±± SAEJ1703 or FMVSS No. 116, DOT 3
±
BRAKE SYSTEM PREPARATIONBR±5
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CHECK AND ADJUSTMENT
BR0EC±07
BRAKE PEDAL CHECK AND
ADJUSTMENT
1. CHECK THAT PEDAL HEIGHT IS CORRECT
Pedal height from asphalt sheet:150.4±160.4 mm (5.92±6.31 in.)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Disconnect the connector from the stop light switch.
(b) Loosen the stop light switch lock nut and remove the stop light switch.
(c) Loosen the push rod lock nut.
(d) Adjust the pedal height by turning the pedal push rod.
(e) Tighten the push rod lock nut.
Torque: 25 N Vm (260 kgf Vcm, 19 ft Vlbf)
(f) Install the stop light switch and turn it until it lightly contacts
the pedal stopper.
(g) Turn the stop light switch back one turn.
(h) Check the clearance (A) between stop light switch and pedal.
Clearance:
0.5±2.4 mm (0.02±0.09 in.)
(i) Tighten the stop light switch lock nut.
(j) Connect the connector to the stop light switch.
(k) Check that the stop lights come on when the brake pedal isdepressed, and go off when the brake pedal is released.
(l) After adjusting the pedal height, check the pedal free±play.
HINT: If clearance (A) between the stop light switch and the
brake pedal stopper has been adjusted correctly, the pedal
freeplay will meet the specifications.
3. CHECK THAT PEDAL FREEPLAY IS CORRECT, AS SHOWN
(a) Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster.
(b) Push in the pedal by hand until the beginning of the second point of resistance is felt, then measure the distance, as
shown.
Pedal freeplay:
1±6 mm (0.04±0.24 in.)
If incorrect, check the stop light switch clearance. And if the
clearance is OK, then troubleshoot the brake system.
HINT: The freeplay to the first point of resistance is due to the
play between the clevis and pin. It is 1±3 mm (0.04±0.12 in.)
on the pedal.
±
BRAKE SYSTEM CHECK AND ADJUSTMENTBR±7
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3. BLEED MASTER CYLINDERHINT: If the master cylinder has been disassembled or if the
reservoir becomes empty, bleed the air from the master cylin-
der.
(a) Disconnect the brake lines from the master cylinder.
(b) Slowly depress the brake pedal and hold it.
(c) Block off the outer holes with your fingers, and release the brake pedal.
(d) Repeat (b) and (c) 3 or 4 times.
4. BLEED BRAKE LINE
(a) Connect the vinyl tube to the brake caliper.
(b) Depress the brake pedal several times, then loosen the
bleeder plug with the pedal held down.
(c) At the point when fluid stops coming out, tighten the bleeder plug, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the fluid has been bled
out.
(e) Repeat the above procedure to bleed the air out of the brake
line for each wheel.
Torque: 11 N Vm (110 kgf Vcm, 8 ft Vlbf)
5. CHECK FLUID LEVEL IN RESERVOIR
Check the fluid level and add fluid if necessary.
Fluid:
SAE J1703 or FMVSS NO.116DOT3
6. INSTALL RESERVOIR CAP
(a) Align the matchmark on the reservoir cap with the matchmark
on the ªopenº side of reservoir.
(b) Push down on the reservoir cap and turn it clockwise until it locks.
(c) Check that the matchmark on the reservoir cap is now aligned with the matchmark on the ªcloseº side of the
reservoir.
±
BRAKE SYSTEM CHECK AND ADJUSTMENTBR±9
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